Segmental Bridge Technology Established and Evolving. W. Jay Rohleder, Jr, P.E., S.E. Senior Vice President / Project Development FIGG

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1 1 Segmental Bridge Technology Established and Evolving W. Jay Rohleder, Jr, P.E., S.E. Senior Vice President / Project Development FIGG

2 2 Segmental Bridge Topics Addressed Definition of concrete segmental bridge construction methods and related design considerations. The evolution of concrete segmental bridge technology over the past 30 years in the U.S. Design principles and practices that provide the economic and durability value for this structure type. Continuing evolution of the segmental bridge construction technology and related design concepts.

3 3 Definition of Segmental Bridges Bridges, that are typically concrete box structure types, constructed using repetitive elements that are progressively connected together to form a completed structure. Construction Load Cases are particularly critical considerations in developing the design and building methods for segmental bridges.

4 4 SEGMENTAL BRIDGE APPLICATIONS URBAN BRIDGES LONG SPAN BRIDGES ENVIRONMENTALLY SENSITIVE LONG BRIDGES OVER WATER ARCHES CABLE STAYED BRIDGES RAIL BRIDGES

5 5 Segmental Bridge Methods, Components and Evolution of the Technique

6 6 Segmental Construction Methods SPAN-by-SPAN (Precast) CANTILEVER (Precast or Cast-in-Place) > Balanced > Uni-Directional INCREMENTAL LAUNCH (Typically an Inefficient use of materials, so Not commonly used need tangent or constant curvature)

7 7 Segmental Construction Methods Span by Span JFK AirTrain, NY City

8 8 Segmental Construction Methods Balanced Cantilever Sagadahoc Bridge, ME

9 9 Segmental Construction Methods Uni-Directional Cantilever (shown) Mixed Methods Garcon Point Bridge, FL

10 10 Precast Joints Keys (i.e. no reinforcing across joints) Epoxy Temporary Clamping Temperature

11 11 Cast-in-Place Joints Reinforcing Bars Joint Preparation Bulkheads

12 12 Post-Tensioning (PT) Arrangements Placement Type Internal Tendons External Tendons Layout Orientation Longitudinal Span by Span Cantilever Transverse Vertical

13 13 Post-Tensioning (PT) Arrangements Internal Tendons Transverse Longitudinal (Cantilever)

14 14 Internal Transverse Pre-Stressing Pre-Tensioning Post-Tensioning

15 15 Post-Tensioning (PT) Arrangements External Tendons, Longitudinal Single Point Deviators

16 16 Post-Tensioning (PT) Arrangements External Tendons, Longitudinal Multi-Point Deviators

17 17 Post-Tensioning (PT) Arrangements Vertical Tendons (in Precast Piers)

18 18 Construction Engineering Camber Geometry Control Prestressing Parameters Erection Loads Erection Equipment Casting and Erection Manuals Integrated Shop Drawings

19 19 Precasting Yard Operations Pre-Tied Reinforcing Cage Jigs Casting Beds > Long Line > Short Line Storage & Delivery

20 Long Line Segment Casting 20

21 Short Line Segment Casting 21

22 22 TYPICAL CASTING YARD LAYOUT Segments in Storage Possible Double Stack Casting Beds Segment Storage Rebar Jigs Batch Plant

23 23 9 Miles of Elevated Precast Segmental Bridge JFK AirTrain, NY, NY

24 24 Precasting Facility - JFK AirTrain 5,500 Segments 14 Casting Cells

25 25 Precasting Facility - JFK AirTrain

26 26 Precasting Facility - JFK AirTrain Segment Delivery

27 27 I-93 Viaducts & Ramps, Boston, MA

28 28 Precasting Facility I-93 Viaducts, Boston Precast plant 85 miles away by truck 85 Miles

29 29 Precasting Facility I-93 Viaducts, Boston Precast plant in Sanford, ME 15 Acres 1250 Segments Casting Cells 4 Typ., 1 Combined

30 30 Precasting Facility I-93 Viaducts, Boston Central concrete delivery - casting 3 beds / day

31 31 Precasting Facility Susquahanna River, PA Total Segments (958 Typical, 82 Specialty) 3 - Typical Casting Cells 1 - Specialty Casting Cell

32 32 Assembly Line Reinforcing Cage Jig Susquehanna River Bridge, PA

33 33 Assembly Line Casting Bed Set-Up Susquehanna River Bridge, PA

34 34 Match Cast Segment Wet Cast Segment

35 Assembly Line Segment Pour 35

36 36 Assembly Line Steam Cured Segments Susquehanna River Bridge, PA

37 37 Segment Storage Handling, Lifting with Strap under Wing Susquehanna River Bridge, PA

38 38 Segment Handling Lifting with Bars through Lifting Holes

39 39 Segment Storage Three Point Supports

40 40 Segment Storage Double Stacking

41 41 PRECAST SUPERSTRUCTURE Comparison Table Project: Susq. I-93 JFK Victory Sagadahoc (Pa.) (Ma.) (NY) (NJ) (Maine) No. Segments Max. Wt. (Tons) No. Typical Beds Casting Yard Size - 20 A 15 A N/A N/A 12 A Cast 1 Segment / Day / Bed

42 42 Precast Segmental Span-by-Span Construction

43 43 Typical Span-by-Span Erection A SECTION A-A A

44 44 Typical Span-by-Span Erection Advance Truss to Next Span

45 45 Typical Span-by-Span Erection Deliver Segments Set Segments

46 46 Typical Span-by-Span Erection Deliver Segments Set Segments

47 47 Typical Span-by-Span Erection Deliver Segments Set Segments Epoxy Joints Join Segments

48 48 Typical Span-by-Span Erection Deliver Segments Set Segments Epoxy Joints Align Pier Segm.

49 49 Typical Span-by-Span Erection Deliver Segments Set Segments Epoxy Joints Align Pier Segm. Thread Tendons Cast Closure

50 50 Typical Span-by-Span Erection Stress Tendons Lower Truss and Repeat Process A SECTION A-A A

51 51 Precast Span-by-Span Segments Erected using: - Underslung Trusses - Overhead Gantry - Falsework Supports

52 52 ERECTION TRUSSES Under Bottom Soffit

53 53 ERECTION TRUSSES Under Wings Deck Designed for Support Condition

54 54 ERECTION with OVERHEAD GANTRY

55 ERECTION TRUSS SUPPORTS Tower on Foundation 55

56 ERECTION TRUSS SUPPORTS Pier Bracket 56

57 57 Specialized Erection Equipment Delivery of Segments from Above WMATA, VA

58 58 SPAN-BY-SPAN CONSTRUCTION EXAMPLE May 2007 Susquehanna River Bridge, PA

59 59 Pennsylvania Turnpike Commission Casting Yard Bridge East Approach Susquehanna River Bridge, PA

60 60 East End Calver Island West End Existing Bridge New EB New WB Casting Yard Twin Bridges with each: 5,910 Long by 57 Wide 40 Spans 150, River Piers 18 Land Piers Susquehanna River Bridge, PA

61 61 TWO ONE THREE ERECTION PHASES Susquehanna River Bridge, PA

62 62 Casting Yard Access Road Segment Erection Susquehanna River Bridge, PA

63 63 Segments Delivered from Storage Susquehanna River Bridge, PA

64 64 Segments Delivered from Above Susquehanna River Bridge, PA

65 65 Susquehanna River Bridge, PA

66 66 Susquehanna River Bridge, PA

67 67 Susquehanna River Bridge, PA

68 68 Segment Alignment Susquehanna River Bridge, PA

69 69 Susquehanna River Bridge, PA

70 70 Susquehanna River Bridge, PA

71 71 ELEVATION SECTION VIEWS Susquehanna River Bridge, PA

72 72 Susquehanna River Bridge, PA

73 73 Activities Off the Critical Path Susquehanna River Bridge, PA

74 74 Achieved Typical Span x Span Erection Rate of 2 Spans per Week Susquehanna River Bridge, PA

75 75 VERTICAL CLEARANCES RAILROAD LINES LOCAL AIRPORT Susquehanna River Bridge, PA

76 76 November NTP May New Bridge Complete Susquehanna River Bridge, PA

77 77 ADVANTAGES OF SPAN-BY-SPAN Quick, Simple Erection (2-3 Spans / Week) Easy Geometry Control Savings from less MOT Minimum User Delays Cost Effective Simple Design Durable Structures Beautiful Bridges

78 78 Precast Segmental Balanced Cantilever Construction

79 79 Balanced Cantilever Erection ERECTION SEQUENCE I

80 80 Balanced Cantilever Erection ERECTION SEQUENCE II

81 81 Balanced Cantilever Erection ERECTION SEQUENCE III ERECTION SEQUENCE IV

82 82 Precast Balanced Cantilever Segments Erected using: - Barge-mounted cranes - Ground based cranes - Beam and Winch - Overhead Gantry

83 83 BALANCED CANTILEVER EXAMPLE September 2007 Twin 3,971 Long Bridges Main Span Unit 330, 440, Tall Precast Piers SxS Appr., B.C. Main Span Unit Victory Bridge, NJ

84 84 Victory Bridge, NJ

85 85 Victory Bridge, NJ

86 86 Victory Bridge, NJ

87 87 Victory Bridge, NJ

88 88 Victory Bridge, NJ

89 89 Victory Bridge, NJ

90 90 Victory Bridge, NJ

91 91 Balanced Cantilever Erection Average production: 4 to 6 segments/day (45 ft) Victory Bridge, NJ

92 92 1st Bridge Open to Traffic in 15 mo. 2nd Bridge Completed in 9 mo. Victory Bridge, NJ

93 93 Cast-in-Place Segmental Balanced Cantilever Construction

94 94 1,248 Long Twin Bridges with 398 Main Spans Wabasha Street Bridge, MN

95 95 Wabasha Street Bridge, MN

96 96 Continue through the Winter Wabasha Street Bridge, MN

97 97 Blending shapes, texture and color Wabasha Street Bridge, MN

98 98 Segmental Bridges Mixing Construction Erection Methods

99 99 3,000 Bridge with 420 Main Span over Kennebec River Sagadahoc Bridge, ME

100 Roadway with 2 Cell Box Girder Cast-in-Place Approach Units, with Precast Main Span Unit Sagadahoc Bridge, ME

101 ,000 sf of Structures - Completed Nov I-93 Ramps & Viaducts, Boston MA

102 102 Span-by-Span Construction I-93 Ramps & Viaducts, Boston MA

103 103 Balanced Cantilever Construction I-93 Ramps & Viaducts, Boston MA

104 104 Span-by-Span Approaches One-Directional Cantilever Main Span CIP low level piers P/C high level piers Mid-Bay Bridge, FL

105 105 Precast Segmental Piers

106 106 Precast Piers Erect 1 Segment an Hour, Approximately 1 Pier per Day Direction of Erection

107 107 Victory Bridge, NJ

108 108 Precast Piers First segment cast 6 weeks after NTP Victory Bridge, NJ

109 109 Precast Piers Casting Bed Victory Bridge, NJ

110 110 Typical Precast Pier Details

111 111 Precast Pier Erection Victory Bridge, NJ

112 112 Precast Pier Erection Victory Bridge, NJ

113 113 Precast Pier Erection Victory Bridge, NJ

114 114 Precast Pier Erection Victory Bridge, NJ

115 115 Precast Pier Erection Victory Bridge, NJ

116 116 Precast Pier Erection Victory Bridge, NJ

117 117 Completed Precast Piers First pier erected 5 months after NTP Victory Bridge, NJ

118 118 Cable Stayed Segmental Superstructure

119 119 1st concrete cable-stayed bridge in the Northeast 1995 U.S. Senator William V. Roth Jr. Bridge over C&D Canal, DE

120 120 Entirely Precast Segmental Bridge U.S. Senator William V. Roth Jr. Bridge over C&D Canal, DE

121 121 Segmental Cable-Stay Bridges I-280 Veterans Glass City Skyway, Ohio 1,225 main span ) Open June 2007 Open Dec Penobscot Narrows Bridge & Observatory, Maine (1,161 main span)

122 122 Veterans Glass City Skyway Precast Superstructure Completed in 8 Months New Penobscot Narrows Bridge Cast-in-Place Superstructure Completed in 15 Months

123 123 Penobscot Narrows Bridge & Observatory, ME

124 124 CIP Balanced Cantilever Construction Form Traveler Form Traveler Penobscot Narrows Bridge & Observatory, ME

125 125 Penobscot Narrows Bridge & Observatory, ME

126 126 Penobscot Narrows Bridge & Observatory, ME

127 127 Carbon Fiber Composite Strand Demonstration Project Penobscot Narrows Bridge & Observatory, ME

128 128 Veteran s Glass City Skyway, Ohio Veteran s Glass City Skyway, OH

129 129 Typical Pre-Cast Cross-Sections: Main Span Veteran s Glass City Skyway, OH

130 130 Main Span Precast Segmental Construction Backspans: Span-by Span Mainspan: One-Directional Cantilever Veteran s Glass City Skyway, OH

131 131 3 pairs of segments erected in cantilever Epoxied segment joints Segments post-tensioned Veteran s Glass City Skyway, OH

132 132 Segmental Bridge Construction Benefits Rapid Construction Segments Delivered over Completed Spans No Need for Barge Delivery Maintained Shipping Lanes at All Times Access to Port of Toledo Veteran s Glass City Skyway, OH

133 133 Review Questions Define a segmental concrete bridge structure type? List 3 methods for constructing segmental bridges? List benefits during construction that result from using a segmental bridge construction technique? List permanent bridge site layout benefits resulting from using a segmental box girder bridge type? What structural benefits apply to using a closed cell box girder for a segmental bridge? What segmental bridge technological advances offer the most immediate benefits?

134 134 Open-ended Assignment Questions Can you identify a viable candidate location for a segmental bridge given your understanding of the potential benefits from using this structure type? What new innovative applications of the segmental bridge construction technique can you envision?

135 135 America Deserves Beautiful Bridges

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